Snap-in extensions and guide walls for bus bar bridges of a battery module

ABSTRACT

The present disclosure includes a battery module having a group of electrically interconnected electrochemical cells, a battery module terminal configured to be coupled to a load for powering the load, and an electrical path extending between the group of electrically interconnected electrochemical cells and the battery module terminal, where the electrical path includes a bus bar bridge. The battery module also includes a housing, where the group of electrically interconnected electrochemical cells is disposed within the housing, and the housing includes a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and to block movement of the bus bar bridge in at least one direction.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 62/100,001, filed Jan. 5, 2015,entitled “MECHANICAL AND ELECTRICAL ASPECTS OF LITHIUM ION BATTERYMODULE WITH VERTICAL AND HORIZONTAL CONFIGURATIONS,” which is herebyincorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure relates generally to the field of batteries andbattery modules. More specifically, the present disclosure relates topositioning and retention of bus bar bridges of a battery module.

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present disclosure,which are described below. This discussion is believed to be helpful inproviding the reader with background information to facilitate a betterunderstanding of the various aspects of the present disclosure.Accordingly, it should be understood that these statements are to beread in this light, and not as admissions of prior art.

A vehicle that uses one or more battery systems for providing all or aportion of the motive power for the vehicle can be referred to as anxEV, where the term “xEV” is defined herein to include all of thefollowing vehicles, or any variations or combinations thereof, that useelectric power for all or a portion of their vehicular motive force. Forexample, xEVs include electric vehicles (EVs) that utilize electricpower for all motive force. As will be appreciated by those skilled inthe art, hybrid electric vehicles (HEVs), also considered xEVs, combinean internal combustion engine propulsion system and a battery-poweredelectric propulsion system, such as 48 Volt (V) or 130V systems. Theterm HEV may include any variation of a hybrid electric vehicle. Forexample, full hybrid systems (FHEVs) may provide motive and otherelectrical power to the vehicle using one or more electric motors, usingonly an internal combustion engine, or using both. In contrast, mildhybrid systems (MHEVs) disable the internal combustion engine when thevehicle is idling and utilize a battery system to continue powering theair conditioning unit, radio, or other electronics, as well as torestart the engine when propulsion is desired. The mild hybrid systemmay also apply some level of power assist, during acceleration forexample, to supplement the internal combustion engine. Mild hybrids aretypically 96V to 130V and recover braking energy through a belt or crankintegrated starter generator. Further, a micro-hybrid electric vehicle(mHEV) also uses a “Stop-Start” system similar to the mild hybrids, butthe micro-hybrid systems of a mHEV may or may not supply power assist tothe internal combustion engine and operates at a voltage below 60V. Forthe purposes of the present discussion, it should be noted that mHEVstypically do not technically use electric power provided directly to thecrankshaft or transmission for any portion of the motive force of thevehicle, but an mHEV may still be considered as an xEV since it does useelectric power to supplement a vehicle's power needs when the vehicle isidling with internal combustion engine disabled and recovers brakingenergy through an integrated starter generator. In addition, a plug-inelectric vehicle (PEV) is any vehicle that can be charged from anexternal source of electricity, such as wall sockets, and the energystored in the rechargeable battery packs drives or contributes to drivethe wheels. PEVs are a subcategory of EVs that include all-electric orbattery electric vehicles (BEVs), plug-in hybrid electric vehicles(PHEVs), and electric vehicle conversions of hybrid electric vehiclesand conventional internal combustion engine vehicles.

xEVs as described above may provide a number of advantages as comparedto more traditional gas-powered vehicles using only internal combustionengines and traditional electrical systems, which are typically 12Vsystems powered by a lead acid battery. For example, xEVs may producefewer undesirable emission products and may exhibit greater fuelefficiency as compared to traditional internal combustion vehicles and,in some cases, such xEVs may eliminate the use of gasoline entirely, asis the case of certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improvedpower sources, particularly battery modules, for such vehicles. Forexample, in traditional configurations, battery modules may includecomponents configured to provide electrical communication between one ormore terminals of the battery module and a group of electricallyinterconnected electrochemical cells of the battery module.Unfortunately, traditional configurations may include expensivecomponents to provide the electrical communication (e.g., electricalpath) between the group of electrically interconnected electrochemicalcells and the one or more terminals of the battery module. Further,manufacturing processes to position said components and to enable theelectrical communication may be expensive and inefficient. Accordingly,it is now recognized that improved components and manufacturingprocesses for electrically coupling electrochemical cells and terminalsof a battery module are desired.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. Itshould be understood that these aspects are presented merely to providethe reader with a brief summary of certain embodiments and that theseaspects are not intended to limit the scope of this disclosure. Indeed,this disclosure may encompass a variety of aspects that may not be setforth below.

The present disclosure relates to a battery module having a group ofelectrically interconnected electrochemical cells, a battery moduleterminal configured to be coupled to a load for powering the load, andan electrical path extending between the group of electricallyinterconnected electrochemical cells and the battery module terminal,where the electrical path includes a bus bar bridge. The battery modulealso includes a housing, where the group of electrically interconnectedelectrochemical cells is disposed within the housing, and the housingincludes a pair of extensions positioned along sides of the bus barbridge and configured to retain the bus bar bridge and to block movementof the bus bar bridge in at least one direction.

The present disclosure also relates a battery module having a housing,electrochemical cells disposed in the housing, a major terminal, and anelectrical path extending between the electrochemical cells and themajor terminal. The electrical path includes an S-shaped bus bar bridgehaving a first base, a second base, and an S-bend extending between thefirst and second bases. The housing includes a first extension extendingupwardly and proximate to a first side of the S-shaped bus bar bridge,and a second extension extending upwardly and proximate to a second sideof the S-shaped bus bar bridge opposite to the first side. The first andsecond extensions are configured to block movement of the S-shaped busbar bridge along at least one axis of the S-shaped bus bar bridge.

The present disclosure also relates to a battery module having anelectrical path extending between a group of electrically interconnectedelectrochemical cells and a terminal of the battery module, where theterminal is configured to be coupled to a load for powering the load.The battery module also includes a bus bar bridge of the electricalpath. Further, the battery module includes at least one snap-inextension integrally formed with a housing of the battery module anddisposed immediately adjacent the bus bar bridge, wherein the at leastone snap-in extension comprises a hook extending over the bus bar bridgeand the at least one snap-in extension is configured to at leasttemporarily block movement of the bus bar bridge in at least onedirection.

DRAWINGS

Various aspects of this disclosure may be better understood upon readingthe following detailed description and upon reference to the drawings inwhich:

FIG. 1 is a perspective view of a vehicle having a battery systemconfigured in accordance with present embodiments to provide power forvarious components of the vehicle;

FIG. 2 is a cutaway schematic view of an embodiment of the vehicle andthe battery system of FIG. 1;

FIG. 3 is an overhead exploded perspective view of an embodiment of abattery module for use in the vehicle of FIG. 1, in accordance with anaspect of the present disclosure;

FIG. 4 is a perspective view of an embodiment of the battery module ofFIG. 3, in accordance with an aspect of the present disclosure;

FIG. 5 is a front view of an embodiment of the battery module of FIG. 3,in accordance with an aspect of the present disclosure;

FIG. 6 is a front schematic view of an embodiment of snap-in extensionsand a bus bar bridge, taken along line 6-6 in FIG. 5, for use in thebattery module of FIG. 3, in accordance with an aspect of the presentdisclosure;

FIG. 7 is a side schematic view of an embodiment of snap-in extensions,a bus bar bridge, and other components for use in the battery module ofFIG. 3, in accordance with an aspect;

FIG. 8 is a front schematic view of an embodiment of guide walls and abus bar bridge for use in the battery module of FIG. 3, in accordancewith an aspect of the present disclosure;

FIG. 9 is a side schematic view of an embodiment of guide walls, a busbar bridge, and other components for use in the battery module of FIG.3, in accordance with an aspect of the present disclosure;

FIG. 10 is a top schematic view of an embodiment of a bus bar bridge, inaccordance with an aspect of the present disclosure; and

FIG. 11 is a schematic view of an embodiment of an electrical path foruse in the battery module of FIG. 3, in accordance with an aspect of thepresent disclosure; and

FIG. 12 is a process flow diagram of an embodiment of a method ofsecuring a bus bar bridge of the battery module of FIG. 3, in accordancewith an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effortto provide a concise description of these embodiments, not all featuresof an actual implementation are described in the specification. Itshould be appreciated that in the development of any such actualimplementation, as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

The battery systems described herein may be used to provide power tovarious types of electric vehicles (xEVs) and other high voltage energystorage/expending applications (e.g., electrical grid power storagesystems). Such battery systems may include one or more battery modules,each battery module having a number of battery cells (e.g., lithium-ion(Li-ion) electrochemical cells) arranged and electrically interconnectedto provide particular voltages and/or currents useful to power, forexample, one or more components of an xEV. As another example, batterymodules in accordance with present embodiments may be incorporated withor provide power to stationary power systems (e.g., non-automotivesystems).

In accordance with embodiments of the present disclosure, the batterymodule may include a group of electrically interconnectedelectrochemical cells disposed in a housing of the battery module. Thebattery module may also include two terminals (e.g., module terminals ormajor terminals) extending outwardly from the housing and configured tobe coupled to a load for powering the load. Two corresponding electricalpaths may be defined between the group of electrically interconnectedelectrochemical cells and the two corresponding terminals of the batterymodule. For example, a first electrical path may be established betweenthe group of electrically interconnected electrochemical cells and afirst terminal (e.g., a first major terminal) of the battery module. Asecond electrical path may be established between the group ofelectrically interconnected electrochemical cells and a second terminal(e.g., a second major terminal) of the battery module.

In certain embodiments, the electrical paths between the group ofelectrically interconnected electrochemical cells and the two terminalsof the battery module may include corresponding transitions between afirst and second material. For example, the electrochemical cells may beelectrically interconnected via bus bars that include the first material(e.g., aluminum). The two major terminals (and/or other components ofthe battery module, such as a shunt) that are configured to be coupledto the load may include the second material (e.g., copper), which maycost less than the first material but may not be compatible with theelectrochemical cells and thus, may not be used for the bus bars.Accordingly, components that enable the transition between the first andsecond materials (e.g., of the bus bars and of the major terminals,respectively) may be included in both of the first and second electricalpaths. For example, a bi-metal bus bar may be disposed in both the firstand second electrical paths to enable the transition from the firstmaterial (of the bus bars) to the second material (of the majorterminals) in each of the paths. The bi-metal bus bars may bebi-metallic, and may each include a first end having the first materialand coupled to a first component (e.g., a terminal of one of theelectrochemical cells or a bus bar extending from one of the terminalsof one of the electrochemical cells) of the electrical path having thefirst material, and a second end having the second material and coupledto a second component (e.g., a bus bar bridge) of the electrical pathhaving the second material. The bus bar bridges of each electrical pathmay extend between the corresponding bi-metal bus bar and anothercorresponding component of the battery module (e.g., a shunt or relayhaving the second material). Additional bus bar bridges having thesecond material may also be included in each electrical path, as setforth below with reference to the figures, to couple the electricalpaths with the major terminals having the second material.

To couple the bus bar bridges to the appropriate components of theelectrical paths, the bus bar bridges may be welded at either end (e.g.,to the bi-metal bus bar on a first end and to the shunt or relay on asecond end, as described above). However, to enable efficientmanufacturing of the battery module, in accordance with presentembodiments, the housing of the battery module may include snap-inextensions or guide walls that enable temporary retention of the bus barbridges or support for the bus bar bridges in one or more directions.For example, the snap-in extensions or guide walls may be integrallyformed with the housing of the battery module, and may be configured toreceive the bus bar bridges and to enable retention of the bus barbridges (e.g., by blocking movement of the bus bar bridges in one ormore directions), while facilitating exposure of weld points of the busbar bridges to a welding tool. In other words, in certain embodiments,the snap-in extensions or guide walls may enable retention of the busbar bridges while the battery module is oriented in the one or moredirections. Thus, the bus bar bridges may be held in place while thebattery module is oriented complimentary to the retention capabilitiesof the snap-in extensions or guide posts and complimentary to thepositioning of a welding tool along the weld points of the bus barbridges for welding the bus bar bridges to appropriate components of theelectrical paths. Further, the retention mechanisms (e.g., the snap-infeatures) may be minimally invasive (e.g., via sizing and/or positioningof the retention mechanisms), such that a welding tool may access weldpoints on the bus bar bridges to more permanently secure the bus barbridges in the electrical path(s).

To help illustrate, FIG. 1 is a perspective view of an embodiment of avehicle 10, which may utilize a regenerative braking system. Althoughthe following discussion is presented in relation to vehicles withregenerative braking systems, the techniques described herein areadaptable to other vehicles that capture/store electrical energy with abattery, which may include electric-powered and gas-powered vehicles.

As discussed above, it would be desirable for a battery system 12 to belargely compatible with traditional vehicle designs. Accordingly, thebattery system 12 may be placed in a location in the vehicle 10 thatwould have housed a traditional battery system. For example, asillustrated, the vehicle 10 may include the battery system 12 positionedsimilarly to a lead-acid battery of a typical combustion-engine vehicle(e.g., under the hood of the vehicle 10). Furthermore, as will bedescribed in more detail below, the battery system 12 may be positionedto facilitate managing temperature of the battery system 12. Forexample, in some embodiments, positioning a battery system 12 under thehood of the vehicle 10 may enable an air duct to channel airflow overthe battery system 12 and cool the battery system 12.

A more detailed view of the battery system 12 is described in FIG. 2. Asdepicted, the battery system 12 includes an energy storage component 13coupled to an ignition system 14, an alternator 15, a vehicle console16, and optionally to an electric motor 17. Generally, the energystorage component 13 may capture/store electrical energy generated inthe vehicle 10 and output electrical energy to power electrical devicesin the vehicle 10.

In other words, the battery system 12 may supply power to components ofthe vehicle's electrical system, which may include radiator coolingfans, climate control systems, electric power steering systems, activesuspension systems, auto park systems, electric oil pumps, electricsuper/turbochargers, electric water pumps, heated windscreen/defrosters,window lift motors, vanity lights, tire pressure monitoring systems,sunroof motor controls, power seats, alarm systems, infotainmentsystems, navigation features, lane departure warning systems, electricparking brakes, external lights, or any combination thereof.Illustratively, in the depicted embodiment, the energy storage component13 supplies power to the vehicle console 16 and the ignition system 14,which may be used to start (e.g., crank) the internal combustion engine18.

Additionally, the energy storage component 13 may capture electricalenergy generated by the alternator 15 and/or the electric motor 17. Insome embodiments, the alternator 15 may generate electrical energy whilethe internal combustion engine 18 is running. More specifically, thealternator 15 may convert the mechanical energy produced by the rotationof the internal combustion engine 18 into electrical energy.Additionally or alternatively, when the vehicle 10 includes an electricmotor 17, the electric motor 17 may generate electrical energy byconverting mechanical energy produced by the movement of the vehicle 10(e.g., rotation of the wheels) into electrical energy. Thus, in someembodiments, the energy storage component 13 may capture electricalenergy generated by the alternator 15 and/or the electric motor 17during regenerative braking. As such, the alternator 15 and/or theelectric motor 17 are generally referred to herein as a regenerativebraking system.

To facilitate capturing and supplying electric energy, the energystorage component 13 may be electrically coupled to the vehicle'selectric system via a bus 19. For example, the bus 19 may enable theenergy storage component 13 to receive electrical energy generated bythe alternator 15 and/or the electric motor 17. Additionally, the bus 19may enable the energy storage component 13 to output electrical energyto the ignition system 14 and/or the vehicle console 16. Accordingly,when a 12 volt battery system 12 is used, the bus 19 may carryelectrical power typically between 8-18 volts.

Additionally, as depicted, the energy storage component 13 may includemultiple battery modules. For example, in the depicted embodiment, theenergy storage component 13 includes a lithium ion (e.g., a first)battery module 20 and a lead-acid (e.g., a second) battery module 22,which each includes one or more battery cells. In other embodiments, theenergy storage component 13 may include any number of battery modules.Additionally, although the lithium ion battery module 20 and lead-acidbattery module 22 are depicted adjacent to one another, they may bepositioned in different areas around the vehicle. For example, thelead-acid battery module 22 may be positioned in or about the interiorof the vehicle 10 while the lithium ion battery module 20 may bepositioned under the hood of the vehicle 10.

In some embodiments, the energy storage component 13 may includemultiple battery modules to utilize multiple different batterychemistries. For example, when the lithium ion battery module 20 isused, performance of the battery system 12 may be improved since thelithium ion battery chemistry generally has a higher coulombicefficiency and/or a higher power charge acceptance rate (e.g., highermaximum charge current or charge voltage) than the lead-acid batterychemistry. As such, the capture, storage, and/or distribution efficiencyof the battery system 12 may be improved.

To facilitate controlling the capturing and storing of electricalenergy, the battery system 12 may additionally include a control module24. More specifically, the control module 24 may control operations ofcomponents in the battery system 12, such as relays (e.g., switches)within energy storage component 13, the alternator 15, and/or theelectric motor 17. For example, the control module 24 may regulateamount of electrical energy captured/supplied by each battery module 20or 22 (e.g., to de-rate and re-rate the battery system 12), perform loadbalancing between the battery modules 20 and 22, determine a state ofcharge of each battery module 20 or 22, determine temperature of eachbattery module 20 or 22, control voltage output by the alternator 15and/or the electric motor 17, and the like.

Accordingly, the control unit 24 may include one or more processor 26and one or more memory 28. More specifically, the one or more processor26 may include one or more application specific integrated circuits(ASICs), one or more field programmable gate arrays (FPGAs), one or moregeneral purpose processors, or any combination thereof. Additionally,the one or more memory 28 may include volatile memory, such as randomaccess memory (RAM), and/or non-volatile memory, such as read-onlymemory (ROM), optical drives, hard disc drives, or solid-state drives.In some embodiments, the control unit 24 may include portions of avehicle control unit (VCU) and/or a separate battery control module.

An overhead exploded perspective view of an embodiment of the batterymodule 20 for use in the vehicle 10 of FIG. 2 is shown in FIG. 3. In theillustrated embodiment, the battery module 20 (e.g., lithium-ion[Li-ion] battery module) includes a housing 30 and electrochemical cells32 (e.g., prismatic lithium-ion [Li-ion] electrochemical cells) disposedinside the housing 30. In the illustrated embodiment, six prismaticLi-ion electrochemical cells 32 are disposed in two stacks 34 within thehousing 30, three electrochemical cells 32 in each stack 34. However, inother embodiments, the battery module 20 may include any number ofelectrochemical cells 32 (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or moreelectrochemical cells), any type of electrochemical cell 32 (e.g.,Li-ion, lithium polymer, lead-acid, nickel cadmium, or nickel metalhydride, prismatic, and/or cylindrical), and any arrangement of theelectrochemical cells 32 (e.g., stacked, separated, orcompartmentalized).

As shown, the electrochemical cells 32 may include terminals 36 (e.g.,cell terminals, minor terminals) extending upwardly (e.g., in direction37). Accordingly, the terminals 36 may extend into an opening 38disposed in an upper side 40 or face of the housing 30. For example, theelectrochemical cells 32 may be inserted into the housing 30 through theopening 38 in the upper side 40, and positioned within the housing 30such that the terminals 36 of the electrochemical cells 32 are disposedin the opening 38. A bus bar carrier 42 may be disposed into the opening38 and may retain bus bars 44 disposed thereon and configured tointerface with the terminals 36 of the electrochemical cells 32. Forexample, the bus bars 44 may interface with the terminals 36 toelectrically couple adjacent electrochemical cells 32 together (e.g., toform a group of electrically interconnected electrochemical cells 32).The bus bars 44 may be mounted or disposed on or proximate to a top or abottom face or surface of the bus bar carrier 42 (e.g., facing away fromthe electrochemical cells 32 or facing the electrochemical cells 32).However, in other embodiments, the battery module 20 may not include thebus bar carrier 42 and the bus bars 44 may be disposed directly onto theterminals 36.

Depending on the embodiment, the bus bars 44 may couple theelectrochemical cells 32 in series, in parallel, or some of theelectrochemical cells 32 in series and some of the electrochemical cells32 in parallel. In general, the bus bars 44 enable a group ofelectrically interconnected electrochemical cells 32. Further, certainof the bus bars 44 may be configured to enable electrical coupling ofthe group of electrically interconnected electrochemical cells 32 withmajor terminals 46 (e.g., module terminals) of the battery module 20,where the major terminals 46 are configured to be coupled to a load(e.g., component(s) of the vehicle 10) to power the load. A cover 54 maybe disposed over the bus bar carrier 42 to seal the opening 38 in thehousing 30 of the battery module 20 and/or to protect the bus bars 44,other components disposed on the bus bar carrier 42, and/or othercomponents of the battery module 20.

In accordance with present embodiments, the bus bars 44 (e.g., disposedon the bus bar carrier 42) may include two major bus bars 56 configuredto enable electrical communication between the group of electricallyinterconnected electrochemical cells 32 and the major terminals 46. Forexample, the two major bus bars 56 may extend beyond a perimeter 58 ofthe bus bar carrier 42 (e.g., in direction 61) and may each define atleast a portion of a corresponding electrical path between the group ofelectrically interconnected electrochemical cells 32 and the majorterminals 46. The major bus bars 56 may include a first material (e.g.,aluminum) corresponding with a material of the terminals 36 of theelectrochemical cells 32 and with the bus bars 44 (e.g., minor bus barsor cell bus bars). In accordance with present embodiments, each majorbus bar 56 may extend from the group of electrically interconnectedelectrochemical cells 32 toward another component of the correspondingelectrical path extending between the group of electricallyinterconnected electrochemical cells 32 and the corresponding majorterminal 46.

For example, the major bus bars 56 may each extend toward acorresponding bi-metal bus bar 59 that facilitates transition of theelectrical path from the first material (e.g., aluminum) to a secondmaterial (e.g., copper), which will be described in detail withreference to later figures. In the illustrated embodiment, only onebi-metal bus bar 59 is shown in one of the electrical paths, although itshould be noted that the other of the electrical paths may also includethe bi-metal bus bar 59. As shown, the bi-metal bus bar 59 may becoupled on a first end to the major bus bar 56, and on a second end toanother component of the electrical path. For example, in theillustrated embodiment, one of the electrical paths (e.g., having theillustrated bi-metal bus bar 59) includes a shunt 60 coupled to aprinted circuit board (PCB) 62 of the battery module 20, where the shunt60 includes the second material (e.g., copper) and the PCB 62 detects inthe shunt 60 a voltage, a temperature, and/or other important parametersof the electrical path and the battery module 20 in general. Inaccordance with present embodiments, bus bar bridges 64 having thesecond material (e.g., copper) may be included in the electrical path oneither end of the shunt 60. For example, one bus bar bridge 64 extendsbetween, and couples to, the second end (e.g., copper end) of thebi-metal bus bar 59 and the shunt 60. It should be noted that thecoupling of the bus bar bridge 64 to the bi-metal bus bar 59 is blockedfrom view in the illustrated embodiment by the housing 30. Another busbar bridge 64 extends between, and couples to, the shunt 60 and anothercomponent of the electrical path (e.g., the major terminal 46 or aconnecting piece between the bus bar bridge 64 and the major terminal46). It should be noted that the coupling of the bus bar bridge 64 andthe other component of the electrical path (e.g., the major terminal 46or connecting piece between the major terminal 46 and the bus bar bridge64) is blocked from view in the illustrated embodiment by the housing30.

In accordance with the present disclosure, the bus bar bridges 64 may beat least temporarily retained (e.g., before being welded to thecomponents of the electrical path described above) via snap-inextensions or guide walls extending from the housing 30 (e.g.,integrally formed with the housing 30), where the snap-in extensions orguide walls block movement of the bus bar bridges 64 in at least onedirection or along one axis (e.g., along axis 37 [longitudinal axis withrespect to the bus bar bridges 64], axis 61 [axis along a thickness ofthe bus bar bridges 64], or axis 66 [axis along the width of the bus barbridges 64]). It should be noted that the bus bar bridges 64 may coupleto a component of the battery module 20 other than the PCB 62 (e.g., toa relay or switch). For example, in the illustrated embodiment, the busbar bridges 64 are only shown for one of the electrical paths, but theother electrical path may include bus bar bridges 64 coupled to a relayor switch. It should also be noted that, in other embodiments, theelectrical paths may include other components that facilitate transitionbetween the first and the second materials, and that the bus bar bridges64 may couple to such other components.

Turning now to FIGS. 4 and 5, a perspective view and a front view,respectively, of an embodiment of the battery module 20 of FIG. 3 isshown. In the illustrated embodiments, as previously described, theshunt 60 of one of the electrical paths may be coupled to the PCB 62,where the PCB 62 (or signals of the PCB 62 or of the battery module 20)detects and/or analyzes operating parameters or conditions of thebattery module 20 (e.g., of the electrical path having the shunt 60).The electrical path also includes the bus bar bridges 64, whichelectrically couple the shunt 60 to the electrically interconnectedelectrochemical cells 32 within the housing 30 of the battery module 20and to the major terminal 46 of the battery module 20 (e.g., the majorterminal 46 configured to be coupled to a load). Further, as previouslydescribed, the housing 30 may include snap-in extensions 70 (or guidewalls) through which the bus bar bridges 64 extend, where the snap-inextensions 70 retain the bus bar bridges 64 (e.g., block movement of thebus bar bridges 64) in one or more directions (e.g., along axis 37, axis61, axis 66, or a combination thereof).

As shown in the illustrated embodiments, the battery module 20 mayinclude one electrical path for each major terminal 46. For example, asshown, one electrical path extends through the shunt 60 coupled to thePCB 62, while the other electrical path extends through a relay 71 ofthe battery module 20. The relay 71 may be a switch (or include a switchmechanism) that enables coupling and decoupling of the electrical path.For example, the switch mechanism of the relay 71 may be opened todisconnect the circuit between the two major terminals 46 (and havingthe group of electrically interconnected electrochemical cells 32 andtwo electrical paths) of the battery module 20. The switch mechanism ofthe relay 71 may be closed to connect the circuit between the two majorterminals 46 of the battery module 20. The electrical path having therelay 71 (or coupled to the relay 71) may also include bus bar bridges64, where the bus bar bridges 64 extend from either end of the relay 71or component of the relay 71. Thus, the electrical path extends from theelectrochemical cells 32, through the bi-metal bus bar 59, through oneof the bus bar bridges 64, through the relay 71 (or component thereof),through the other one of the bus bar bridges 64, and to the majorterminal 46.

It should be noted that the snap-in extensions 70 may include hooks 72that extend inwardly and over the bus bar bridge 64. For example, across-sectional schematic view of an embodiment of a pair of snap-inextensions 70, taken along line 6-6 in FIG. 5 and for use in the batterymodule 20 of FIG. 3, is shown in FIG. 6. In the illustrated embodiment,each snap-in extension 70 includes a hook 72 (e.g., triangle, righttriangle, triangular prism, point, pointed hook) extending toward theother extension 70 of the pair. For example, each hook 72 may include apoint 73 that points toward the other extension 70. Put differently,each hook 72 may be triangular (e.g., a right triangle) having adownwardly and inwardly sloping surface 74 that slopes toward the point73. The surface 74 may enable pushing of the bus bar bridge 64 throughthe surface 74 and into place under a lower flat surface 77 of each hook72, where the lower flat surface 77 of each hook 72 may be substantiallyparallel with a top surface 79 of the bus bar bridge 64. Further, thehooks 72 may facilitate retention of the bus bar bridge 64 (e.g., byblocking movement of the bus bar bridge 64), at least temporarily, indirection 61. Wall posts 75 of the snap-in extensions 70 may facilitateretention of the bus bar bridge 64 (e.g., by blocking movement of thebus bar bridge 64), at least temporarily, along direction 66.

A side schematic view of an embodiment of the snap-in extensions 70, busbar bridge 64, shunt 60, and PCB 62 is shown in FIG. 7. In theillustrated embodiment, the bus bar bridge 64 is S-shaped and includes afirst base 80, a second base 82, and an S-bend 84 extending between thefirst base 80 and the second base 82. The first base 80 is configured tobe coupled (e.g., welded) to a component (not shown) of the electricalpath (e.g., as described with reference to FIGS. 3-5). The second base82, as previously described, may be configured to be coupled (e.g.,welded) to the shunt 60. In the illustrated embodiment, the snap-inextensions 70 are generally disposed proximate to (e.g., in-line with)the first base 80 along direction 37. However, in other embodiments, thesnap-in extensions 70 may be disposed proximate to (e.g., in-line with)the S-bend 84 of the bus bar bridge 64, the second base 82 of the busbar bridge 64, the first base 80 (as described above), or a combinationthereof. In general, the snap-in extensions 70 retain (e.g., block atleast some movement of) the bus bar bridge 64 in at least one direction(e.g., direction 66, direction 37, direction 61, or a combinationthereof). For example, the snap-in extensions 70 may block at least somemovement of the bus bar bridge 64 via the hooks 72 (shown in FIG. 6)contacting the upper surface 79 (shown in FIG. 7) of the bus bar bridge64 (e.g., along direction 61), via the hooks 72 (shown in FIG. 6)contacting the S-bend 84 (shown in FIG. 7) of the bus bar bridge 64(e.g., along direction 37), and via the snap-in extensions 70 contactingsides of the bus bar bridge 64 (e.g., along direction 66). However, insome embodiments, as indicated by arrow 99 (shown in FIG. 7), thesnap-in extensions 70 may extend above the upper surface 79 of the busbar bridge 64 and above the S-bend 84, such that the S-bend 84 would notcontact the hooks 72 (shown in FIG. 6) if slid along direction 37. Insuch embodiments, the snap-in extensions 70 may only block movement ofthe bus bar bridge 64 in directions 66 and 61.

It should be noted that, in some embodiments, guide walls 90 (e.g.,extensions) may be included in place of, or in addition to, snap-inextensions 70. For example, a cross-sectional schematic view of theguide walls 90 and a portion of the bus bar bridge 64 is shown in FIG.8. In the illustrated embodiment, the guide walls 90 include only thewall posts 75 (e.g., without the hooks). Thus, the guide walls 90 mayonly block movement (at least temporarily) of the bus bar bridge 64 indirection 66. However, in another embodiment, the guide walls 90 mayinclude the hooks (e.g., the hooks 72 in FIGS. 3-7), and, thus, may bereferred to as snap-in extensions in embodiments having the hooks.Further, it should be noted that “extensions” encompasses both thesnap-in extensions 70 and the guide walls 90.

A side schematic view of the guide walls 90 is shown in FIG. 9. In theillustrated embodiment, the guide walls 90 are disposed proximate to(e.g., in-line with) the S-bend 84. However, the guide walls 90 may bedisposed proximate to (e.g., in-line with) any portion of the bus barbridge 64, including the S-bend 84, the first base 80, the second base82, or a combination thereof.

It should also be noted that, in certain embodiments, the guide walls 90(or snap-in extensions 70) may not be included in pairs and/or may beincluded along other surfaces of the bus bar bridge 64. For example, aschematic top view of the bus bar bridge 64 is shown in FIG. 10. In theillustrated embodiment, the bus bar bridge 64 includes two longitudinalsides 100, 102 extending along the first base 80, the S-bend 84, and thesecond base 82 of the bus bar bridge 64. The bus bar bridge alsoincludes two transverse sides 104, 106 extending between thelongitudinal sides 100, 102, where the first transverse side 104 extendsalong the first base 80 of the bus bar bridge 64 and the secondtransverse side 106 extends along the second base 82 of the bus barbridge 64. One or more guide walls 90 or snap-in extensions 70 may beincluded along any one of the longitudinal sides 100, 102 and/ortransverse sides 104, 106.

It should be noted that, in the illustrated embodiment, the bus barbridge 64 is sized and shaped such that the bus bar bridge 64, ifrotated 180 degrees about axis 66, is substantially positioned the sameand capable of its same intended function and connectibility as it wasprior to rotating the bus bar bridge 64 180 degrees about axis 66. Inother words, because of the S-shaped nature of the bus bar bridge 64,the bus bar bridge 64 may be flipped 180 degrees about axis 66 and wouldstill fit into place in the electrical path. This feature increases easeof manufacturing and interchangeability of parts. It should also benoted that, in accordance with present embodiments, all of the bus barbridge 64 of one electrical path may be substantially the same in shapeand size. This feature also enables increased ease of manufacturing andinterchangeability of parts. In some embodiments, all of the bus barbridges 64 of the entire battery module 20 may be interchangeable.

A schematic view of an embodiment of an electrical path 120 of thebattery module 20 is shown in FIG. 11. The electrical path 120 extendsbetween one electrochemical cell 32 or two or more electricallyinterconnected electrochemical cells 32 (e.g., illustrated optionally asdashed lines) and one major terminal 76 (e.g., module terminal) of thebattery module 20. In the illustrated embodiment, the electrical path120 includes the bus bar bridge 64, and may include any number of othercomponents. The illustrated embodiment also includes one or more snap-inextensions 70 and/or guide walls 90. As shown, the snap-in extensions 70and/or guide walls 90 may be disposed along any side or surface of thebus bar bridge 64. It should also be noted that more than one bus barbridge 64 and corresponding snap-in extensions 70 and/or guide walls 90may be included, as previously described. The snap-in extensions 70and/or guide walls 90 provide at least temporary retention of the busbar bridge(s) 64 before, during, and/or after welding of the bus barbridge(s) into place in the electrical path 120.

A process flow diagram of an embodiment of a method 150 of securing thebus bar bridge 64 of the battery module 20 of FIG. 3 is shown in FIG.12. The method 150 includes positioning the bus bar bridge 64 proximateto one or more extensions (e.g., the snap-in extensions 70 or the guidewalls 90) (block 152). For example, the bus bar bridge 64 may bepositioned between a pair of extensions, where the extensions blockmovement of the bus bar bridge 64 in at least one direction.

The method 150 also includes positioning the bus bar bridge 64 withinthe electrical path 120 (block 154). For example, the bus bar bridge 64may be positioned within the electrical path 120 such that the bus barbridge 64 is in position to be welded to one or more components (e.g.,the bi-metal bus bar 59, the shunt 60, the relay 71, or some othercomponent of the electrical path 120). Indeed, the bus bar bridge 64 maybe positioned in contact with the one or more components of theelectrical path 120.

Further, the method 150 includes orienting the battery module 20 suchthat weld points of the bus bar bridge 64 are accessible by a weldingtool (block 156). For example, as previously described, the extensions(e.g., the snap-in extensions 70 and/or the guide walls 90) may bepositioned such that weld points of the bus bar bridge 64 are accessibleby the welding tool, and such that the bus bar bridge 64 remains inposition during the welding process. Thus, the battery module 20 may bemoved such that the welding tool can access the weld points, while theextensions retain the bus bar bridge 64 in place.

Further still, the method 150 includes welding the bus bar bridge 64 tothe appropriate components of the electrical path 120 (block 158). Forexample, the welding tool may heat weld points of the bus bar bridge 64and/or press against the bus bar bridge 64 to weld the bus bar bridge 64to the appropriate components of the electrical path 120. Additionallyor alternatively, other welding processes may be used to weld the busbar bridge 64 into place. Any welding process (e.g., ultrasonic welding,laser welding, diffusion welding) suitable for welding the bus barbridge 64 to the appropriate components of the electrical path 120 iswithin the scope of present embodiments.

One or more of the disclosed embodiments, alone or in combination, mayprovide one or more technical effects useful in the manufacture ofbattery modules, and portions of battery modules. In general,embodiments of the present disclosure include a battery module havingelectrical paths extending between a group of electricallyinterconnected electrochemical cells and major terminals (e.g., moduleterminals) of the battery module. The electrical paths may each includeone or more bus bar bridges. Snap-in extensions or guide walls of thehousing may enable at least temporary retention of the bus bar bridge(s)before, during, and/or after the bus bar bridge(s) is/are welded intoplace in the electrical paths. The technical effects and technicalproblems in the specification are exemplary and are not limiting. Itshould be noted that the embodiments described in the specification mayhave other technical effects and can solve other technical problems.

The specific embodiments described above have been shown by way ofexample, and it should be understood that these embodiments may besusceptible to various modifications and alternative forms. It should befurther understood that the claims are not intended to be limited to theparticular forms disclosed, but rather to cover all modifications,equivalents, and alternatives falling within the spirit and scope ofthis disclosure.

1. A lithium-ion (Li-ion) battery module, comprising: a group of electrically interconnected electrochemical cells; a battery module terminal configured to be coupled to a load for powering the load; an electrical path extending between the group of electrically interconnected electrochemical cells and the battery module terminal, wherein the electrical path comprises a bus bar bridge; and a housing, wherein the group of electrically interconnected electrochemical cells is disposed within the housing, and wherein the housing comprises a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and to block movement of the bus bar bridge in at least one direction.
 2. The Li-ion battery module of claim 1, wherein the pair of extensions is configured to block movement of the bus bar bridge only along a transverse axis of the bus bar bridge.
 3. The Li-ion battery module of claim 1, wherein the pair of extensions is configured to block movement of the bus bar bridge only along a transverse axis of the bus bar bridge and a longitudinal axis of the bus bar bridge perpendicular to the transverse axis.
 4. The Li-ion battery module of claim 1, wherein the pair of extensions is configured to block movement of the bus bar bridge only along a transverse axis of the bus bar bridge, a longitudinal axis of the bus bar bridge perpendicular to the transverse axis, and an axis along a thickness of the bus bar bridge perpendicular to both the transverse and longitudinal axes.
 5. The Li-ion battery module of claim 1, wherein the bus bar bridge comprises an S-shape having a first base, a second base, and an S-bend extending between the first base and the second base.
 6. The Li-ion battery module of claim 5, wherein the first base of the bus bar bridge extends between the extensions of the pair of extensions.
 7. The Li-ion battery module of claim 5, wherein the S-bend extends between the extensions of the pair of extensions.
 8. The Li-ion battery module of claim 5, wherein the housing comprises an additional pair of extensions positioned along the sides of the bus bar bridge and configured to retain the bus bar bridge and to block movement of the bus bar bridge in at least one direction, wherein the first base of the bus bar bridge extends between the extensions of the pair of extensions, wherein the second base of the bus bar bridge extends between the additional extensions of the additional pair of extensions, and wherein the pair of extensions and the additional pair of extensions extend in a first vertical direction substantially parallel to at least the portion of the S-bend of the bus bar bridge.
 9. The Li-ion battery module of claim 1, wherein each extension of the pair of extensions comprises a hook that extends toward the other extension of the pair of extensions and over at least a portion of the bus bar bridge.
 10. The Li-ion battery module of claim 9, wherein the hook of each extension comprises a corresponding right triangle having a base facing a first portion of the bus bar bridge and parallel with the first portion of the bus bar bridge.
 11. The Li-ion battery module of claim 1, wherein the group of electrically interconnected electrochemical cells comprises a group of electrically interconnected prismatic lithium-ion (Li-ion) electrochemical cells.
 12. The Li-ion battery module of claim 1, wherein the bus bar bridge is positioned proximate to the pair of extensions such that a first weld point of the bus bar bridge is exposed with sufficient clearance for access via a welding tool on a first side of the pair of extensions, and a second weld point of the bus bar bridge is exposed with sufficient clearance for access via the welding tool on a second side of the pair of extensions opposite to the first side.
 13. The Li-ion battery module of claim 1, wherein the battery module comprises a shunt, and the bus bar bridge is welded to the shunt.
 14. The Li-ion battery module of claim 1, wherein the pair of extensions extend above a first surface of a first base of the bus bar bridge.
 15. The Li-ion battery module of claim 1, wherein the battery module comprises a relay switch mechanism and the bus bar bridge is coupled to a component of the relay switch mechanism.
 16. The Li-ion battery module of claim 1, wherein the housing and the pair of extensions are plastic, and the pair of extensions is integrally formed with the housing.
 17. A lithium-ion (Li-ion) battery module, comprising: a housing; a plurality of electrochemical cells disposed in the housing; a major terminal of the battery module; and an electrical path extending between the plurality of electrochemical cells and the major terminal of the battery module, wherein the electrical path comprises an S-shaped bus bar bridge having a first base, a second base, and an S-bend extending between the first and second bases, wherein the housing comprises a first extension extending upwardly and proximate to a first side of the S-shaped bus bar bridge and a second extension extending upwardly and proximate to a second side of the S-shaped bus bar bridge opposite to the first side, and wherein the first and second extensions are configured to block movement of the S-shaped bus bar bridge along at least one axis of the S-shaped bus bar bridge.
 18. The Li-ion battery module of claim 17, wherein the first and second extensions are together configured to block movement of the S-shaped bus bar bridge along at least a first axis of the S-shaped bus bar bridge and a second axis of the S-shaped bus bar bridge perpendicular to the first axis.
 19. The Li-ion battery module of claim 17, wherein the first and second extensions are together configured to block movement of the S-shaped bus bar bridge along at least a first axis of the S-shaped bus bar bridge, a second axis of the S-shaped bus bar bridge perpendicular to the first axis, and a third axis of the S-shaped bus bar bridge perpendicular to the first and second axes.
 20. The Li-ion battery module of claim 17, wherein the first extension comprises a first pointed edge extending toward the second extension, and the second extension comprises a second pointed edge extending toward the first extension.
 21. A lithium-ion (Li-ion) battery module, comprising: an electrical path extending between a group of electrically interconnected electrochemical cells and a terminal of the battery module, wherein the terminal is configured to be coupled to a load for powering the load; a bus bar bridge of the electrical path; and at least one snap-in extension integrally formed with a housing of the battery module and disposed immediately adjacent the bus bar bridge, wherein the at least one snap-in extension comprises a hook extending over the bus bar bridge and the at least one snap-in extension is configured to at least temporarily block movement of the bus bar bridge in at least one direction.
 22. The Li-ion battery module of claim 21, wherein the hook comprises a first right triangle having a lower flat surface facing a base of the bus bar bridge and parallel with the base.
 23. The Li-ion battery module of claim 21, wherein the bus bar bridge is an S-shaped bus bar bridge having a first base, a second base, and an S-bend extending between the first base and the second base.
 24. The Li-ion battery module of claim 21, wherein the at least one snap-in extension is disposed immediately adjacent the base of the bus bar bridge such that the hook extends over the base of the bus bar bridge. 